Method of designing and fabricating patient-specific restorations from intra-oral scanning of a digital impression coping

ABSTRACT

Taking a digital implant or abutment level digital impression by means of intra-oral, computed tomography or other imaging method provides the restorative doctor and laboratory accurate and effective data for determining the implant position, angulation and locking feature orientation without a physical impression. Such data is correlated with a digital library to produce an output which enables design and fabrication of an accurate restorative device such as a prosthetic tooth or crown. In this way the time-consuming, costly and error prone mechanical replication of the relevant dental anatomy is obviated.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 14/516,981, filed on Oct. 17, 2014, which is a continuation of U.S. patent application Ser. No. 12/800,784, filed on May 21, 2010, which claims priority to and the benefit of U.S. Provisional Application No. 61/217,186, filed on May 27, 2009, the entireties of these applications are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to the design and manufacture of patient-specific dental restorations. More specifically, the invention herein relates to restorations such as implant abutments, screw-retained crowns, implant and abutment over-denture and temporary prostheses at the implant and abutment level.

BACKGROUND DISCUSSION

Dental implants have become the preferred modern alternative for replacing missing natural teeth. Typically, an implant abutment is secured into the underlying bone tissue terminating within the surrounding gum tissue. Eventually, a dental restoration is secured to the implant. The restoration must be designed to match the surrounding teeth in color, size, shape and orientation so that it looks and functions much as the predecessor natural tooth it replaces. However, because of potential variability in the precise position (angulation and vertical position) and locking orientation of the implant, the design of the restoration is also subject to substantial variability.

Conventionally, the restoration is designed by a laboratory using a physical replication of the dental anatomy. This physical replication is obtained by affixing an impression coping, locked to the underlying implant or abutment and extending above the gum line among the surrounding dental structure. Then the area is replicated using dental laboratory techniques and a model is produced. The laboratory then uses this model to design and fabricate the prosthetic restoration. Unfortunately, these various steps are time consuming, costly and potentially error prone.

SUMMARY OF THE INVENTION

The present invention overcomes the noted deficiencies and disadvantages of the prior art laboratory process. The invention herein entirely obviates the need for a physical replication to be sent to a laboratory to provide information for the design and fabrication of an implant restoration. The invention comprises the following steps:

1. A digital impression coping is affixed to the implant or abutment (for an abutment level digital impression) by means of a screw or it is friction retained. Digital impression copings for computed tomography and related imaging methods are made from radiopaque materials.

2. The digital impression coping(s) and surrounding dental anatomy are then imaged via intra-oral, computed tomography or other imaging technology including magnetic resonance imaging (MRI).

3. The scan of the digital impression coping(s) is correlated with reference impression digital impression coping(s) to determine the implant(s) position, angulation and locking feature orientation.

4. A laboratory then utilizes a CAD program that uses the implant(s) or abutment(s) spatial relation to the patient's oral anatomy to design patient-specific prosthetic restoration(s) and create the output file(s) required for its manufacture.

Taking a digital implant or abutment level digital impression by means of intra-oral, computed tomography or other imaging method provides the restorative doctor and laboratory an accurate and effective means of determining the implant position, angulation and locking feature orientation without a physical impression. This digital impression has applications including, but not limited to:

1. Designing and fabricating patient-specific restorations such as implant abutments, screw-retained crowns, implant and abutment level over-denture restorations and temporary prostheses at the implant and abutment level.

2. As a record of a patient's implant and anatomical spatial data on a specific date.

BRIEF DESCRIPTION OF THE DRAWINGS

The aforementioned objects and advantages of the present invention, as well as additional objects and advantages thereof, will be more fully understood hereinafter as a result of a detailed description of a preferred embodiment when taken in conjunction with the following drawings in which:

FIG. 1 is a photograph of a patient's oral anatomy adjacent an implant to which a digital impression coping has been affixed and locked into engagement;

FIG. 2 is a photograph of an intra-oral scanning process of the patient's implant area of FIG. 1;

FIGS. 3A and 3B are images obtained by the scanning process of FIG. 2 showing the precise vertical position, angular orientation and locking engagement of the digital impression coping and adjacent dental anatomy;

FIG. 4 is an image similar to that of FIGS. 3A and 3B, but showing the oral anatomy with a restoration in place of the digital impression coping and positioned in engagement with the underlying implant ready to receive a prosthetic tooth or crown based upon data derived from the originally scanned image; and

FIG. 5 is an image of the relevant anatomy showing placement of a prosthetic implant abutment, designed and fabricated by employing the present invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

This method of digital implant and abutment level impression taking is similar to conventional methods, but the implant position, angulation and locking feature orientation are captured via intra-oral, computed tomography or other imaging methods instead of with physical impression media. The basic components required to capture an implant or abutment level digital impression and design a restoration from the digital impression are:

1. A digital impression coping of known dimension, for implant or abutment level, with a flat, radius, slot or other geometrically distinct feature, or features, for determining the implant position, angulation and locking feature orientation.

2. An intra-oral, computed tomography or other imaging method that can record the digital impression coping(s) and oral anatomy with sufficient accuracy.

3. A means of correlating the scan of the digital impression coping with a reference digital impression coping thereby deriving the implant(s) position, angulation and locking feature orientation.

4. CAD software to design the implant or abutment level restorations and create an output file(s) for additive or subtractive manufacture of the implant or abutment level prosthetic restoration.

The paragraph 1 component is shown in FIG. 1. As seen therein, a digital impression coping 22 has been affixed to the underlying implant in the oral cavity 20 in an area 24. The abutment is in locking engagement with the implant so that its position and orientation (note the flat area 23 at the upper end of the abutment) will provide precise data in regard to the underlying implant. This data becomes evident in a scan of the area being taken as shown in FIG. 2. A number of available intra-oral scanners 26 are available for performing this step. One such scanner, for example, is an IOS FastScan™ Digital Impression System shown in FIG. 2. The resultant images 30, 32 and 34 are shown in FIGS. 3A and 3B. These images represent the type of data that can be electronically transmitted to a laboratory for the area 24 a.

Laboratory personnel maintain a digital library of impression copings that can be correlated to the scan data of the digital impression coping in the patient's mouth. Based upon the digital impression coping length and the location of the “orientating feature” on the upper end of the digital impression coping, three additional types of information can be obtained, namely:

1. The angulation as determined by the angle of the digital impression coping 22 a;

2. The position of the implant restorative connection (i.e., its position with respect to the implant-level, or the abutment level and other important fixed points such as adjacent and opposing contacts); and

3. The locking feature orientation (i.e., where the orientating feature on the digital impression coping matches with a corresponding feature 23 on the implant connection).

The laboratory personnel can then employ these data, derived both from the image and from their library, to utilize CAD software to create an output file 36 (see FIG. 4) of the prosthetic restoration 38 from which the physical restoration 40 is then fabricated and sent to the dentist or implant surgeon who mates it with the implant 25 (see FIG. 5).

Having thus disclosed a preferred embodiment of the invention, it will now be apparent that variation from the described example, is contemplated. By way of example, the image may be derived in ways not specifically described herein and the digital impression coping may be configured with various alternative characteristics which alter the data from that specifically disclosed herein. Accordingly, the scope of the invention herein is not necessarily limited to the specific embodiment depicted, but only by the appended claims and their legal equivalents. 

The invention claimed is:
 1. A method for providing a properly configured dental prosthetic restoration for mating with an implant abutment attached to an implant installed in a patient without requiring a physical impression of the patient's oral cavity, the method comprising the steps of: a) mating a digital impression coping with said abutment, said digital impression coping including at least one geometrically distinct feature for determining the position and angulation of the abutment; b) scanning an image of said digital impression coping and adjacent dental anatomy; c) removing said digital impression coping from said abutment; d) using said scanned image and CAD software to design a restoration to mate directly with said abutment including the step of correlating said scanned image to a library of digital impression coping data; e) additively manufacturing the restoration; and f) installing the restoration onto the abutment in place of the digital impression coping.
 2. The method recited in claim 1 wherein the library of digital impression coping data is representative of a plurality of digital impression copings corresponding to implant abutments of a plurality of different manufacturers.
 3. The method recited in claim 1 wherein step b) comprises the step of producing an oral cavity image which includes at least adjacent and opposing teeth of said patient in relation to said implant abutment.
 4. The method recited in claim 1 wherein step b) comprises using an intra-oral imaging method to scan said image.
 5. The method recited in claim 1 wherein step b) comprises using magnetic resonance imaging (MM) method to scan said image.
 6. The method recited in claim 1 comprising: prior to step a), lockingly engaging said implant abutment to said implant.
 7. A method of designing a dental prosthetic restoration mating with an implant abutment attached to an implant installed in a patient without requiring a physical impression of the patient's oral cavity, the method comprising the steps of: a) affixing a digital impression coping to said abutment, said digital impression coping including at least one geometrically distinct feature for determining the position and angulation of the abutment; b) scanning said digital impression coping; c) removing said digital impression coping from said abutment; d) correlating said scanning of said digital impression coping to a library of digital impression coping data; e) using CAD software to design a restoration to mate directly with said abutment; f) additively manufacturing the restoration; and g) installing the restoration onto the abutment in place of the digital impression coping.
 8. The method recited in claim 7 wherein the library of digital impression coping data is representative of a plurality of digital impression copings corresponding to implant abutments of a plurality of different manufacturers.
 9. The method recited in claim 7 wherein step b) comprises the step of producing an oral cavity image which includes at least adjacent and opposing teeth of said patient in relation to said implant abutment.
 10. The method recited in claim 7 wherein step b) comprises using an intra-oral imaging method to scan said digital impression coping.
 11. The method recited in claim 7 wherein step b) comprises using magnetic resonance imaging (MM) method to scan said digital impression coping.
 12. The method recited in claim 7 comprising: prior to step a), lockingly engaging said implant abutment to said implant.
 13. A method for designing and fabricating a dental prosthetic restoration for mating with a dental implant installed in a patient without requiring a physical impression of the patient's oral cavity, the method comprising the steps of: a) mating a digital impression coping with said dental implant, said digital impression coping including at least one geometrically distinct feature for determining the position and angulation of the dental implant; b) scanning an image of said digital impression coping and adjacent dental anatomy; c) removing said digital impression coping from said dental implant; d) using said scanned image and CAD software to design a restoration to mate directly with said dental implant including the step of correlating said scanned image to a library of digital impression coping data; e) additively manufacturing the restoration; and f) installing the restoration onto the dental implant in place of the digital impression coping.
 14. The method recited in claim 13 wherein the library of digital impression coping data is representative of a plurality of digital impression copings corresponding to dental implants of a plurality of different manufacturers.
 15. The method recited in claim 13 wherein step b) comprises the step of producing an oral cavity image which includes at least adjacent and opposing teeth of said patient in relation to said dental implant.
 16. The method recited in claim 13 wherein step b) comprises using an intra-oral imaging method to scan said image.
 17. The method recited in claim 13 wherein step b) comprises using magnetic resonance imaging (MM) method to scan said image. 